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The hex mesh is from McMaster Carr, see this page https://www.mcmaster.com/#aluminum-sheets-with-openings/=1e2f5u1

The mesh can be painted as I did on this project:https://www.tonymacx86.com/threads/neilhart-what-is-this-old-guard-ex58-ud3r-into-a-prodigy-mini-itx-case.168344/page-2 post # 13, and seems to hold up well. However I like the contrast on this project and I intend to leave it as is.

The panels are cut from 12 x 0.125 inch square 6061 aluminum sheet stock using a Jet brand 10 inch table saw. I have worked to get the saw aligned with the fence slots which allows these cuts with ease.

Then all of the detail cuts for vents and IO are done using a jig saw followed up with a lot of hand filing to the desired cut line.

I also use a floor standing drill press. And battery powered hand drill motor for hole threading.

Modding and custom cases are my hobby and projects like this one are very expensive to the point that the S4 Mini, the Dan case and the Ghost S1 case in comparison are inexpensive. So there is no budget limit on this and other projects.

More to follow
Neil

<blockquote data-quote="neilhart" data-source="post: 108802" data-attributes="member: 1932">The hex mesh is from McMaster Carr, see this page <a href="https://www.mcmaster.com/#aluminum-sheets-with-openings/=1e2f5u1">https://www.mcmaster.com/#aluminum-sheets-with-openings/=1e2f5u1</a>The mesh can be painted as I did on this project:<a href="https://www.tonymacx86.com/threads/neilhart-what-is-this-old-guard-ex58-ud3r-into-a-prodigy-mini-itx-case.168344/page-2">https://www.tonymacx86.com/threads/neilhart-what-is-this-old-guard-ex58-ud3r-into-a-prodigy-mini-itx-case.168344/page-2</a>&nbsp; post # 13, and seems to hold up well.&nbsp; However I like the contrast on this project and I intend to leave it as is.The panels are cut from 12 x 0.125 inch square 6061 aluminum sheet stock using a Jet brand 10 inch table saw.&nbsp; I have worked to get the saw aligned with the fence slots which allows these cuts with ease.<img src="http://www.1neilhart.com/images/saw.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /> Then all of the detail cuts for vents and IO are done using a jig saw followed up with a lot of hand filing to the desired cut line.&nbsp; I also use a floor standing drill press.&nbsp; And battery powered hand drill motor for hole threading.Modding and custom cases are my hobby and projects like this one are very expensive to the point that the S4 Mini, the Dan case and the Ghost S1 case in comparison are inexpensive.&nbsp;&nbsp; So there is no budget limit on this and other projects.More to followNeil</blockquote>

[QUOTE="neilhart, post: 108802, member: 1932"] The hex mesh is from McMaster Carr, see this page [URL]https://www.mcmaster.com/#aluminum-sheets-with-openings/=1e2f5u1[/URL] The mesh can be painted as I did on this project:[URL]https://www.tonymacx86.com/threads/neilhart-what-is-this-old-guard-ex58-ud3r-into-a-prodigy-mini-itx-case.168344/page-2[/URL] post # 13, and seems to hold up well. However I like the contrast on this project and I intend to leave it as is. The panels are cut from 12 x 0.125 inch square 6061 aluminum sheet stock using a Jet brand 10 inch table saw. I have worked to get the saw aligned with the fence slots which allows these cuts with ease. [IMG]http://www.1neilhart.com/images/saw.jpg[/IMG] Then all of the detail cuts for vents and IO are done using a jig saw followed up with a lot of hand filing to the desired cut line. I also use a floor standing drill press. And battery powered hand drill motor for hole threading. Modding and custom cases are my hobby and projects like this one are very expensive to the point that the S4 Mini, the Dan case and the Ghost S1 case in comparison are inexpensive. So there is no budget limit on this and other projects. More to follow Neil [/QUOTE]

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